Gear Drives. A third gear added to the system will rotate in the same direction as the drive gear Equal diameters = Equal number of teeth = Same speed

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1 Gear Drive Systems

2 Gear Drives Gear Drive: Synchronous mechanical drive that uses gears to transfer power Gear: A toothed wheel that meshes with other toothed wheels to transfer rotational power Pinion Gear: Typically the smaller of two meshing gears Meshing of teeth prevents slippage Drive and driven shafts must be located near each other Counter-rotation

3 A third gear added to the system will rotate in the same direction as the drive gear Equal diameters = Equal number of teeth = Same speed Gear Drives

4 Gear ratios : Speed of driven gear compared to drive gear Easiest to use number of teeth on each, but diameter works Gear ratio = N D / N d 1:1 vs. 1:1.6 Gear Drives

5 Idler Gears Transfer motion and direction (doesn t change speed) Work as both drive and driven Can be used when drive/driven too far apart

6 Torque Twisting or rotational force T = F x D T = torque (in lb-ft or lb-in) F = force (in lbs) D = distance (in inches or ft)

7 Spur Gears Straight teeth, parallel to shaft Most common in industry Internal or External Rack and Pinion (rotary to linear)

8 Manufactured in pairs Used in gear boxes Smoother operation than spur gears Mesh in sliding motion Causes axial thrust Helical

9 Herringbone Double Helical Avoids axial (end) thrust Quiet and efficient

10 Bevel Gears Straight, tapered teeth Often used in gear boxes Spiral bevel gears Miter Gears 1:1 ratio Typically 90 degree transfer

11 Worm and Worm Gears Large speed reduction Smooth/quiet operation

12 Lubrication Necessary for gear drive system to function properly Eliminates metal-to-metal contact (reduce friction and wear) Temperature control Prevent rust/corrosion Suspend and carry away contaminates

13 Backlash Backlash : Amount of movement (play) between meshing gear teeth Required to prevent full contact on both sides of teeth Allows flow of lubricant between teeth flanks Too little backlash leads to resistance, overheating or jamming Too much backlash leads to noise (whirring, roaring, clunking), excessive wear, broken teeth, vibration/harmonics

14 Gear Boxes Sealed container with input and output shafts At least one set of mating gears Can change shaft rotation, speed and/or direction In-line and right angle most common Oil reservoir Sight glass or plug

15 Oil Analysis Shows chemical breakdown, contamination levels, particle type and amount

16 Compound Gear Train Two or more gears rotate on one common shaft Produce higher speeds in less space Drives several devices from same shaft

17 Gear Wear Abrasive Wear Material removed due to hard particles Contaminated oil (metal, sand, scale, etc.) Scratches gear teeth

18 Gear Wear Corrosive Wear Metal wear due to acid in system Will often attack entire gear, but greatest on tooth surface Acid forms from oil when it gets hot enough for resins to separate from the oil High temps may be due to overloading, wrong lubricant or old lubricant

19 Gear Wear Electrical Pitting Electric arc discharges across the oil film between teeth Locally melts tooth surface (small craters in tooth surface surrounded by burned or fused metal May be caused by improperly grounded system, static discharges, improper welding connections

20 Gear Wear Rolling and Scuffing Deformed metal on teeth caused by high contact stress, mismatched or misaligned teeth, progressive Rolling Grooves along pitch line and burrs on tips of teeth Scuffing Transfer of metal from tooth to tooth, localized due to tooth mismatch or misalignment

21 Gear Wear Fatigue Wear Created by repeated stresses Cracks leading to fractures Usually begin from the first moment a gear is used (normally unseen and immeasurable) Sufficient vibration can cause rapid fatigue, along with overloading or grinding gears

22 Cam Drives Transmits motion using an irregular external or internal surface Convert rotary motion to linear (or other) motion types

23 Used to connect two shafts Rigid or flexible Couplings

24 Mechanical Flexing Components move/shift to allow for slight misalignment Clearance permits movement Couplings

25 Couplings Material Flexing Uses material that bends/flexes to accommodate shaft misalignment Rubber, plastic, springs or composites

26 Couplings Rigid Couplings Requires precise alignment Able to transmit more power Flange Sleeve

27 Lab! (Finally) Next Week

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